In-line production of linerless labels

Abstract

According to an embodiment of the present disclosure, a method of labeling a plurality of products includes coating a pressure sensitive adhesive to a roll of face stock, the roll of face stock configured to be converted to a plurality of individual labels aligned in a single lane; singulating an individual label from the roll of face stock; and applying the individual label to a product of the plurality of products, wherein the coating, singulating and applying are conducted sequentially in a single continuous operation with a single continuous web of material.

The invention claimed is: 
     
       1. A label laminate comprising:
 a filmic or a paper substrate, said substrate having a first surface and a second surface; 
 a pressure sensitive adhesive (PSA) layer, said PSA layer being tacky and having a first surface and a second surface, the first surface of the PSA being in contact with the second surface of the substrate; and 
 a detack layer on top of the second surface of the PSA layer, said detack layer comprising a mixture of at least a solid tackifier and a solid plasticizer, the tackifier to the plasticizer weight ratio being in the range 25:75 to 75:25, and having a melting point above about 50° C., wherein the detack layer has a surface coverage of less than 100% of the second surface of the PSA layer; 
 wherein the PSA layer to the detack layer weight ratio is in the range of about 1:2 to about 10:1 and the surface coverage is obtained by spraying, printing, sprinkling, sieving, electrostatic deposition, dusting or powder coating the detack layer on top of the second surface of the PSA. 
 
     
     
       2. The label laminate of  claim 1 , further comprising spacers located on top of the second surface of the PSA layer and/or the detack layer to minimize blocking. 
     
     
       3. The label laminate of  claim 1 , wherein the detack layer is provided in a form of a plurality of filaments and/or ellipsoids sprayed on the second surface of the PSA to form the detack layer, the filaments and/or the ellipsoids are of different shapes, lengths and/or thicknesses disposed in a random distribution on top of the second surface of the PSA. 
     
     
       4. The label laminate of  claim 1 , wherein the detack layer is tackifiable in less than 3 seconds upon exposure to a thermal or an infra-red radiation source and upon tackifying, the detack layer begins blending with the PSA layer to form a PSA blend, the detack layer and the PSA blend being tacky, and the detack layer and the PSA blend staying tacky for a period of at least 30 minutes. 
     
     
       5. The label laminate of  claim 1 , wherein the substrate comprises at least a perforated line or a weakened line configured to convert the label laminate to a plurality of individual labels. 
     
     
       6. The label laminate of  claim 1 , wherein the PSA is at least one polymer selected from a group consisting of acrylic polymers, acrylic copolymers, polyurethanes, silicone polymers, copolymers of styrene and butadiene, copolymers of styrene and isoprene, copolymers of styrene and ethylene butylene, wherein the at least one polymer is with or without additives, wherein the acrylic polymer includes a comonomer selected from a group consisting of dioctyl maleate and/or dibutyl fumarate, and wherein the acrylic copolymer is vinyl acrylics. 
     
     
       7. The label laminate of  claim 1 , wherein the PSA has a coat weight of about 3 gsm to about 50 gsm. 
     
     
       8. The label laminate of  claim 1 , wherein the first surface of the substrate is free of any release material, thereby enabling printing an indicia on the first surface of the label laminate. 
     
     
       9. The label laminate of  claim 1 , wherein the PSA is a hot melt pressure-sensitive adhesive. 
     
     
       10. The label laminate of  claim 1 , wherein the pressure-sensitive adhesive is an acrylic pressure sensitive adhesive comprising a tackifier. 
     
     
       11. The label laminate of  claim 1 , wherein the filmic substrate is a plastic film and the label laminate remains clear after exposure to heat to tackify the detack layer, thereby forming a clear label providing a no-label look to a product to which the clear label is applied. 
     
     
       12. The label laminate of  claim 1 , wherein a label can be separated before the detack layer is tackified by an external heat source. 
     
     
       13. The label laminate of  claim 1 , further comprising a reusable interleaf material introduced into the label laminate before rolling the label laminate up for storage and transport. 
     
     
       14. The label laminate of  claim 1 , wherein the label laminate is die cut to provide labels, said labels are stacked to form a magazine, said magazine used to dispense labels. 
     
     
       15. The label laminate of  claim 1 , wherein the label laminate is printed to form labels, said labels are cut, activated and applied to containers. 
     
     
       16. The label laminate of  claim 1 , wherein the PSA is deposited on the filmic or the paper substrate using water based systems selected from a group consisting of emulsion polymers or copolymers, or as viscous syrups, or using solvents, or as hotmelts melted and coated above 100° C., or warm melts melted and coated below about 100° C. 
     
     
       17. A label laminate comprising:
 a filmic or a paper substrate, said substrate having a first surface and a second surface; 
 a pressure sensitive adhesive (PSA) layer, said PSA layer being tacky and having a first surface and a second surface, the first surface of the PSA being in contact with the second surface of the substrate; and 
 a detack layer on top of the second surface of the PSA layer, said detack layer comprising a mixture of at least a solid tackifier and a solid plasticizer, the tackifier to the plasticizer weight ratio being in the range 25:75 to 75:25, and having a melting point above about 50° C., wherein the detack layer has a surface coverage of less than 100% of the second surface of the PSA layer; 
 wherein the substrate comprises at least a perforated line or a weakened line configured to convert the label laminate to a plurality of individual labels and the detack layer is tackifiable in less than 3 seconds upon exposure to a thermal or an infra-red radiation source and upon tackifying, the detack layer begins blending with the PSA layer to form a PSA blend, the detack layer and the PSA blend being tacky, and the detack layer and the PSA blend staying tacky for a period of at least 30 minutes. 
 
     
     
       18. The label laminate of  claim 17 , wherein the PSA layer to the detack layer weight ratio is in the range of about 1:2 to about 10:1 and the surface coverage is obtained by spraying, printing, sprinkling, sieving, electrostatic deposition, dusting or powder coating the detack layer on top of the second surface of the PSA. 
     
     
       19. A label laminate comprising:
 a filmic or a paper substrate, said substrate having a first surface and a second surface; 
 a pressure sensitive adhesive (PSA) layer, said PSA layer being tacky and having a first surface and a second surface, the first surface of the PSA being in contact with the second surface of the substrate; and 
 a detack layer on top of the second surface of the PSA layer, said detack layer comprising a mixture of at least a solid tackifier and a solid plasticizer, the tackifier to the plasticizer weight ratio being in the range 25:75 to 75:25, and having a melting point above about 50° C., wherein the detack layer has a surface coverage of less than 100% of the second surface of the PSA layer; 
 wherein the filmic substrate is a plastic film and the label laminate remains clear after exposure to heat to tackify the detack layer, thereby forming a clear label providing a no-label look to a product to which the clear label is applied and the label laminate is printed to form labels, said labels are cut, activated and applied to containers. 
 
     
     
       20. The label laminate of  claim 19 , wherein the PSA layer to the detack layer weight ratio is in the range of about 1:2 to about 10:1 and the surface coverage is obtained by spraying, printing, sprinkling, sieving, electrostatic deposition, dusting or powder coating the detack layer on top of the second surface of the PSA.